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( Reaffirmed 2001 )

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Is:6619-1972

Indian Standard
SAFETY CODE FOR SEMICONDUCTOR RECTIFIER EQUIPMENT
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Power Convertors Sectional Committee, ETDC 31


Chairman SHRI A. K. KHOSLA Members
SHRI M. S. SRINIVA~A MURTRY ( AItnnatr to Shri A.-K. Khosla ) General Directorate of Posts & Telegraphs ADDmori.%L CHIEF ENGINZER Department, Jabalpur DIRECTOR OF TELEQRAPH~ ( X ) I Alternate 1 DI~IONAL ENGINEER TELEGRAPHS ( XE ) ( Allcrn& j SHRI P. K. BANERIEE Hindustan Steel Limited, Ranchi SHRI S. L. BH~TIA ( Altcrnats ) SHRI M. G. BHAT Automatic Electric Private Ltd. Bombay SHRI S. D. JINSIWALE(Alternate) SHRI J. CHA~ERJEE Usha RectiEer Corporation ( India), Faridabad SHRI S. G. SARDAR ( Alternate) SHRIP. CHAWLA The Fertilizers Corporation of India Ltd, Nangal SHRI S. K. MALIK ( Aitzmate ) General of Supplies & Disposals DEPUTY DIRECTOROF IKSPE~TION Directorate ( Inspection Wing ) SHRI R. K. DHAWAN (Alternate) DIRECTORSTANDARDS (ELEC) Railway Board ( Ministry of Railways ) DEPUTY DXRECYORSTANDARDS ( ELEC 3 ) ( Alternote ) DIRECTOR (TED) Central Water & Power Commission ( Power Wing) DEPUTY DIRECTOR ( TED ) ( Alternafc ) SHRI M. W. DUKLE E. Ruttonsha Private Ltd, Bombay SHRI M.S. PATWARDHAN (Alternate) SHRI T.K. GHOSE The Calcutta Electric Supply Corporation Ltd, Calcutta SHRI P. K. BHA~TACHARJEE ( Al!ernatc ) DR S. K. HAJELA Indian Telephone Industries Ltd, Bangalore SHRI S. T. PILLAI ( Altcrnotc ) SHRI R.G. GSWANI Asia Electric Compar:y, Calcutta SHRI P. T. BUDITNANI ( Alternate ) SRRI S. M. &IER Hind Rectifiers Ltd, Bombay SHRI R. MANMOHAN Elvoc Private Ltd, Calcutta DR J. K. CROUDHURY ( Alfernate )

Representing
Heavy Electricals ( India ) Ltd, Bhopal

( Continuedon page 2 )

INDIAN STANDARDS INSTITUTION MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MAR0 NEW DELi3.I

Is:6619-1972 ( Cmtinwdfrom page 1)


Re@ent& Members Siemena India Ltd, Bombay SERI T. K. h&RA SHRIA. v. CEIINDARKAR ( &tnnfItc) Research & Development Organization for Electrical SHRX S. P. PROTHIA Industries, Bhopal Chi&Dg;py of Electronics, Ministry of SaRr v. s. RAO SHRI S. K. MANI ( Ahmate ) SERI D. IV. SEN SHRI R. K. DWI-T ( Alternote) Smu M. S. SURANA SHRIM. B. TAMBAKED SHRI A. N. TANDON (Alternate) SHRX K. K. TANEIA SHKI G. L. K&wiun (Altcmafe) Smu Y. S. VENKAIZSWMUN, Director ( Elec tech )

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Martin Burn Ltd, Calcutta Hindustan Aluminium Corporation Ltd, Renukoot NGEF Limited, Bangalore Directorate General of Technical Development Director General, IS1 ( &-&& sccre!ug SHRI R. C. JAIN Director (Elec tech ), ISI Member)

As&ant

Is : 6619 - 1972

Indian Standard
SAFETY CODE FOR SEMICONDUCTOR RECTIFIER EQUIPMENT
LICENSED TO ESSAR STEEL LIMITED, HAZIRA FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

0.

FOREWORD

0.1This Indian Standard was adopted by the Indian Standards Institution on 11 May 1972, after the draft finalized by the Power Convertors Sectional Committee had been approved by the Electrotechnical Division Council. 0.2 This safety code for semiconductor rectifier equipment lays down the basic requirements for reasonable safety to persons and property and covers various forms of the fire hazards to property and life or injury to persons. 0.3 This safety code does not cover specific requirements or deviations that may be specified or permitted by applicable codes for specific industries or processes. 0.4 This safety code does not cover specific additional requirements that may be specified to meet unusual service conditions, examples of which are: a) exposure to damaging fumes; b) exposure to excessive moisture; c) exposure to excessive dust; d) exposure to abrasive dust; e) exposure to steam; f) exposure to oil vapour; g) exposure to explosive mixture of dust or gases; h) exposure to salt air; j) exposure to weather or dripping water; k) exposure to abnormal vibration or shock, or both; m) exposure to unusual transportation or storage conditions.
NOTE 1 - Unusual service conditions, where they exist, should be called to the manufacturers attention as rectifier equipment used in such cases may require specific construction or protection. NOTE 2 -For the performance requirements of the type of rectifier equipment covered in the code, reference shall be made to IS: 251 l-1963*, IS : 3136-1965t, IS : 3895-1966$ and IS : 4540-19688. *Specification tSpecification fSpe&cation $Specification for polycrystalline for polycrystalline for monocrystalline for monocrystalline semi-conductor rectifier stacks. semiconductor rectifier equipment. semiconductor rectifier cells and stacks. semiconductor rectilier assemblies and equipment.

IS:6619=1972 0.5 While specifying the various requirements of this code, it is assumed that the rectifier equipment are properly applied, installed and maintained. The supply circuit or rectifier equipment or both are provided with proper protection against short circuit and earth-faults. It is further assumed that suitable disconnecting means are provided in the supply circuit of rectifier equipment and suitable provisions are made for earthing. 0.6 This standard is one of a series of Indian Standards on power convertors. A list of standards published so far in this series is given on P 14. 0.7 In the preparation of this standard, assistance has been derived from NEMA Pub No. RI l-1968 Safety code for semiconductor rectifier equipments issued by National Electrical Manufacturers Association, New York. 0.8 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test, shall be rounded off in accordance with IS : 2-1960*. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. 1. SCOPE 1.1 This safety code applies to complete rectifier equipment for general, industrial and commercial applications using rectifier cells and stacks of germanium, selenium or silicon. 1.2 This safety code does not apply to rectifier equipment of the following types: a) Rectifier-type arc-welding machines, b) Equipment d) Equipment 2. TERMINOLOGY 2.1 For the purpose of this standard, XXVII )-1969-t shall apply. 3. GENERAL 3.1 Applications - This safety code covers rectifier equipment the following applications: a) Electroplating and electrochemical processes; used for definitions given in IS : 1885 ( Part built for railway traction, arc and exciter lamp power supplies, and in which the output voltage exceeds 5 000 V dc. c) Motion-picture

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*Rules for rounding off nume-rical values ( rmiscd). tElectrotechuka1 vocabulary: Part XXVII Static power convcrtora.

IS : 6619 - 1972
b) Charging c) Charging batteries; d) Cathodic industrial general protection; output truck type batteries; purpose communication and central station

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e) Aircraft ground power supplies; f) General purpose power conversion equipment for all dc voltages, including regulated and non-regulated types. 3.2 Construction

shall be provided with an enclo3.2.1 Enclosure - A rectifier equipment sure which shall house all live parts operating above the safe voltage. Adequate precautions shall be taken as agreed to between the purchaser and the supplierto avoid accidental contact with the exposed live parts by any unauthorized person. live 3.2.2 Door or Cover - A door or cover giving access to uninsulated parts shall be provided with means for holding it securely in place except for those parts which are operating below the safe voltage. If designed to give access to fuses or other parts whose normal functioning requires renewal or replacement, a door or cover shall be either hinged or sliding, or similarly attached so as to prevent its being easily removed. 3.2.3 Steel Sheet Thickness - The minimum thickness required for steel sheet enclosures varies with the size of the enclosure. Based on the use of solid steel sheet without any openings other than those required for operating handles or shafts or for ventilation, the thickness shall be not less than that given below and not less than 0.90 mm at points where rigid conduit is connected:
Maximum Panel Width (see Notes 1 to 3 ) Minimum Thickness of Steel Sheet

mm 125 250 500 750 1 500 2 000


NOTE 1 The width is the smaller dimension

mm 0.63 0.90 1.60 2.00 2.50 3.15


of a rectangular panel.

NOTE 2 -The maximum width implies the width of a rectangular panel supported at all four edges. Adjacent panels may have edge supports in common and be made of single sheet. Supported at the edge means fastened to, resting against or otherwise having a relatively solid support, stiffening member or adequate reinforcement so as to

ls:6619-1972
or minimize the bending of the panel at the edge. Narrow panels supported long edge and two short edges, with or without stiffening means along the opposite long edge depending upon the resulting structural rigidity, are considered satisfactory. prevent

along

one

NOTE 3 - It is not the intention of this code to describe fully the means which may be employed to provide adequate rigidity for the enclosure structure, but to specify the minimum thickness permissible.

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3.2.4 Supporting Frame - All enclosures which are composed ofwire mesh, or grille work or both shall be provided with a perforated screens supporting frame rigid enough to prevent mesh screens or grille work or both from being deformed and making contact with live circuit parts. 3.2.5 Ventilating Openings 3.2.5.1 Ventilating openings in an enclosure, including perforated holes, louvers and openings protected by means of wire screening, expanded metal or perforated covers, shall be of such a size or shape that no opening will permit the passage of a rod having a diameter greater than 12 mm, except that when the distance between live parts and the enclosure is greater than 100 mm, openings may be larger than 12 mm, provided that no opening will permit the passage of a rod having a diameter greater than 18 mm. 3.2.5.2 The diameter of the wires of a screen shall be not less than l-60 mm when the screen openings are 1.60 cm2 or less in area and shall be not less than 2.50 mm for larger screen openings. 3.2.5.3 Except as given in 3.2.5.4, sheet metal employed in expanded metal mesh and perforated sheet metal shall be not less than l-25 mm in thickness when the mesh openings or perforations are I.60 cm* or less in area and shall be not l.ess than 2.50 mm in thickness for larger openings. 9.2.5.4 In a small rectifier unit where the indentation of a guard or enclosure will not affect the clearance between uninsulated movable current carrying parts and earthed metal, reduced sheet thickness may be employed, as agreed to between the purchaser and the supplier, taking into consideration the shape and size of the enclosure. 3.2.6 Floor-Mounted Rectijier Equipment 3.2.6.1 When specified, a covering is required over the bottom of floor-mounted casing except when the enclosure of floor-mounted equipment ( rated 600 volts or less ) is within 150 mm of the floor and exposed live parts are not less than 150 mm above the lower edge. 3.2.6.2 min proof. Vermin-proofing -When specified, the enclosure shall be ver-

3.2.7 Outdoor Use - Rectifier equipment which are intended for permanent outdoor use shall be of suitable weatherproof construction or should be housed in weatherproof enclosures. Where supplementary housing is used, the temperature rise of the enclosed equipment shall be investigated.

IS : 6619 - 1972
3.3 Mechanical Assembly

3.3.1 The assembly of a rectifier equipment shall be such that it will not be affected adversely by the vibrations encountered in normal operation. 3.3.2 A control switch, lampholder, attachment plug receptacle, or plug connector provided as a part of a rectifier equipment shall be mounted securely and shall be prevented from turning by means other than friction between surfaces. 3.3.3 Ferrous by enamelling, such unprotected 4. CLEARANCE metal parts shall be suitably protected against corrosion galvanizing, plating or equivalent means if the failure of parts would be liable to result in a hazardous condition. AND CREEPAGE DISTANCES ) to
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conductors 4.1 The distance from non-arcing uninsulated live .parts the following parts shall be not less than that shown in Ta b le 1: 4 Similar parts of opposite polarity ( phase-to-phase ).

b)

Metal parts ( other than enclosure walls ) which may be earthed when the rectifier equipment is installed ( phase-to-earth ). exIjosed unearthed enclosure metal (including parts. fittings ) for conduit or a metal nrmoured cable.

C>Externally 4 Walls of

4.2 These clearances and creepage distances shall not apply to relays, contactors, instruments, and other components or to parts which are hermetically sealed or encapsulated ( diodes, transistors, thyristors ), provided that their clearance and creepage distances conform to the relevant Indian Standards for these components. The spacings for all components not covered by Indian Standards shall conform to those given in Table 1, 4.3 The creepage distances shown in Table be increased for dirty or moist conditions. 1 for clean, dry surfaces should

4.3.1 The use of protective coatings, such as varnish, to improve resistance to contamination, shall not warrant reduced clearances and oreepage distances. 4.3.2 The spacings given in Table 1 are based on the available current which can be limited by the source or by a transformer, reactor, voltage divider, current-limiting fuses or similar devices in the circuit. The ordinary fuses or circuit breakers ( except high-speed current-limiting devices ) shall not be considered as current-limiting devices. 4.4 Where the peak voltage on which the device is used is more than times the rms voltage, the peak voltage shall be divided by d??to obtain equivalent circuit voltage. 7 1.5 the

IS : 6619 - 1972
4.5 For altitudes above 1 000 m, the circuit voltage shall be divided by the following derating factor before using the table:

Altitude Me&es 1001 to 1200

Derating Factor 0.98


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1201 ), 1500 1 501 ,, 3 000


4.6 An

0.95
0.80

insulating lining or barrier employed where spacing would otherwiqe be insufficient shall be not less than 0.8 mm in thickness and shall be so located that it cannot be adversely affected by arcing or shall be arc resistant. 4.6.1 If a live or current-carrying part is not rigidly supported, or if a movable non-current-carrying metallic part is in proximity to a live part, the construction shall be such that the minimum spacings shown in Table 1 shall be maintained. The spacings between surfaces shall not be maintained by friction alone. 5.

WIRING AND INSULATING

MATERIALS

5.1 The wiring

of rectifier equipment covered by this code shall be such as to comply with the requirements of IS : 732-1963* and IS : 2274-19637 wherever applicable. They shall employ materials which are acceptable for the particular use. The workmanship and the finish should be in keeping with good engineering practices.

5.2 Wirirfg shall be smooth and entirely free from sharp edges, burrs, fins, moving parts, etc, which may cause abrasion of the insulation of conductors. 5.3 A cor.ductor subjected to a total operating temperature higher than 90C shall, if insulated, have asbestos or some other high-temperature insulation or shall be provided with beads of non-carbonizable material or the equivalent so applied as to maintain the required spacings. A bare conductor or a conductor utilizing beads of insulation shall not be employed outside of an enclosure. 5.4 All splices and connections shall be mechanically secure and shall have adequate current-carrying capacity. If the nature or location or both of a soldered connection is such that loosening of the solder is likely to occur, and if such loosening of solder may result in any earthing or short-circuitbg of live parts or other hazardous conditions, the connection shall he made mechanically secure before soldering.
*Code of practice for electrical wiring installations 650 volts ) ( revised ) . tCode of practice for electrical wiring installations 650 volts ).

( system v&age
(system

not

exceeding exceeding

voltage

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TABLE

MINIMUM

SPACINGS PHASE-TO-PHASE
(Clauses 4:1, 4.2,4.3, 4.3.2 and4.6.1

AND )

PHASE-TO-EARTH

CIRCUIT #--__-__-h__ 8C

VOLTAoR

VOLTS \

CONTROL ~_A----~

CrRCUIT

dc

. Through
Air

r-

POWER CIRCUIT -__-h-__--_----\ Circuit Fault Current Level 10 kA and Above Less than 10 kA r--h-_-_-_~ -_U-, Through Through Alon dry ,X,, air air sur tT ace (5) mm (6) mm (7) mm (8) mm

(1) (rm4
up 51 126 251 501 601 1201 1801 to to ,, ,, ,, ,, ,, ,, 50 125 250 500 600 ! 200 1600 2500 up 51 126 251 501 751 1501 2001

(2)

(3) mm

(4)
mm 6 10 13 25 -

to to 3, ,, ,,

50 125 250 500 750

3 5 5 6 -

3 6 10 10 -

6 10 13 25 -

13 19 25 25 38 50 64

19 32 51 51

,) 1 500 ,, ,, 2000 3000

64
70 76 t s Y 2

5.5 A splice shall be provided with insulation suitable for the temperature and potential involved if permanence of spacing between the splice and non-current-carrying metal parts is not assured. 5.6 The space within enclosures shall be sufficient to provide ample room for the distribution of wires and cables required for proper wiring.
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5.7 Insulated conductors, either single, bunched or cabled, when passing through openings in sheet metal walls shall be effectively protected by suitable bushings or well-rounded surfaces against which the conductors may bear. 5.8 Rubber-insulated conductors, except those with oil-resisting compounds, shall not be used where they may be exposed to oil, grease, oily vapour or other substances having a deleterious effect on rubber. 5.9 The internal wiring shall consist of suitable insulated having adequate current-carrying capacity for the service. 5.10 Wherever insulated wire is connected to a resistance insulation shall be non-combustible or slow-burning. conductors element, the

5.11 Low-potential circuit wiring of 60 V or less may be cabled together with or run in the same wireway as wiring of higher potential circuits provided that all of the wiring has insulation suitable for use at the highest potential. 5.12 Strain relief shall be provided SO that a mechanical strain on a flexible cord will not be transmitted to terminals, splices or interior wiring. - 5.13 At a point where a flexible cord passes through an opening in a wall barrier or enclosing case, there shall be a suitable bushing or the equivalent which shall be substantial, be reliably secured in place, and have a smooth rounded surface against which the cord may bear. 5.14 If insulated grommets are to be accepted in lieu of insulating bushings, the insulating material shall be not less than 080 mm thick and shall completely fill the space between the grommet and the metal in which it is mounted. 5.15 Soft rubber bushings of good quality may be used if the bushing is not less than 1.12 mm thick and if the hole in which the bushing is mounted is free from projections, sharp edges, burrs, etc, and if the temperature of the parts in contact is less than SOOC. 5.16 Bare live parts, including conductors, shall be so secured to their bases or mounting surfaces that they will be prevented from so turning or shifting as to reduce the required spacing between conductors and earthed parts. Friction alone shall not be used to prevent the turning of live parts; a suitable lock-washer may be properly applied. The security of 10

Is : 6619 - 1972
contact assembiies contacts. shall be such as to ensure the continued alignment of

5.17 Bare low-potential live parts shall be supported on heat-resisting and moisture-resisting insulating material such as phenolic composition, porcelain, cold-moulded composition or some suitable equivalent which will withstand the most severe conditions liable to be met with in the service. 5.18 Vulcanized fibre may be used for insulating bushings, washers, separators and barriers but shall not be used as the sole support for bare live parts except in low-potential circuits of 60 V or less. 6. OOMPONENTS 6.1 A traniformer which is supplied as a part of a stationary .rectifier equipment shall be of the double winding type; except that an autotransformer may be employed if the primary rating is not more than 250 V and if the rectifier equipment is a part of the assembly which it supplies, or if the rectifier equipment is provided with a solid through connection which is designed and marked for the attachment of the earthed conductor of the supply circuit and the rectifier voltage does not exceed 300 V dc. 6.2 A transformer which is provided as a part equipment shall be of the double winding type. of portable rectifier

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6.3 The transformer or reactor coils shall be wound in a workmanlike manner, treated with an insulating varnish and baked or otherwise impregnated to exclude moisture or acid vapour. 6.4 A switch which is provided as part of a rectifier equipment shall be suitable for the particular application and shall have a current and voltage rating not less than that of the circuit which it controb when the device is operating under normal conditions and shall be capabIe of withstanding maximum available fault currents. 6.5 If a primary circuit-breaker or fuses are provided, their rating shall be in accordance with the maximum input to the rectifier equipment and they shall be capable of interrupting the maximum available short-circuit current of ac system. 6.6 The overload relays shall be so designed and connected as to ensure reliable and positive electrical and mechanical performance for their int+endedpurpose under all conditions of operation. 6.7 Automatic tripping of overload relays shall be independent pulation of the handle. 6.8 If overload relays are adjustable, they shall be either suitably of manimarked

Es I6619-

1972

7. TEMPERATURE 7.1 Materials employed in the construction of a rectifier equipment shall not be affected adversely by the temperatures given below under normal operating conditions: Sl
No. i) Material and Component Part Maximum Allowable Temperature C

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Bare buses, connecting

bars, terminals

85* 85 90 95 120 170

ii) iii) iv) v) vi) vii) viii)

Varnished cloth insulation Fibre as electrical insulation Class A insulation Class B insulation Class H insulation Phenolic composition Insulated conductors electrical and cords insulationt

150 See the relevant Indian Standards

7.2 Rectifier equipment, when tested under normal operating conditions at full-load output, shall not attain a temperature at any point sufficiently high to constitute a fire hazard or to affect injuriously any material employed in the units, nor show temperature-rises at a specific point greater than those indicated in 7.1. 7.2.1 Materials and components will be considered as being affected injuriously if they are subjected to temperatures greater than those specified in the individual relevant Indian Standards pertaining to the materials or components. The conditions of loading during this test shall be indicated under rtiting except that, if a rectifier is obviously not intended for continuous full-load operation, the test may be conducted so that it will take into consideration the rated intermittent or short-time operation of the equipment. 7.3 \\:hen a rectifier equipment is tested in accordance with its rating, the total temperature of buses, connecting straps, or terminals shall not exceed 80C. This safety cczle does not apply to connectors to a source of heat such.as resistors, thermoheaters, etc. 8. RA~INQ 8.1 The primzry input in amperes or voltamperes shall not exceed the marked ratin,i by more than 10 percent when the rectifier equipment is *For maximum ambient temperature of 40C. tThe limitations on rubber insulation and phenolic compositions do not apply to com12

pounds whxh have been recognized as having special heat-resisting properties.

IS : 6619 - 1972
operated from a supply circuit of rated voltage ing maximum rated voltage and current.
NATE 1 -This connected to: test may be made with

and frequency
of the

and

deliverequipment

the output

rectifier

a) the load for which the rectifier is intended, b) a suitable resistance load, c) a fully discharged charger, or battery (see Note 2 ) of suitable rating for a battery capacitor

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d) a direct-current generator as a substitute for a battery or a resistor substitute for a battery. further information for NOTE 2 -For Indian Standards for batteries. 8.2

discharged battery please refer to the relevant

A rectifier equipment having voltage-regulating and current-regulating taps, or both, shah be tested when adjusted so that maximum primary current is obtained under maximum rated output conditions.
NomClauses 8.1 and 8.2 are not applicable for large size semi-conductor equipment designed for electro-chemical or electro-metallurgical duties.
rectifier

9. MARKING 9.1 A rectifier equipment shall be clearly visible after the equipment is installed. shall be indicated. 9.2 The marking normal operating marked where it will be readily The polarity of the output leads during the

may be located behind a door if it is visible or servicing of the rectifier equipment.

10. DIELECTRIC TESTS 10.1 The insulation and spacings of a rectifier equipment temperature or while heated ( following the temperature capable of withstanding without breakdown for a period of application of a 50 Hz alternating potential of 1 000 V primary voltage or 2 000 V whichever is greater between parts of the primary circuit and: a) non-current-carrying b) current-carrying metal parts of an insulated secondary either at room test) shah be one minute the plus twice rated current-carrying and

parts which may be earthed, circuit.

10.2 An insulated secondary circuit shall be capable of withstanding a similar test, except that the applied potential for a secondary circuit of 60 V or less (open circuit ) shall be 600 V and the applied potential for a circuit of 61-90 V (open circuit ) shall be 900 V,

13

INDIAN ON

STANDARDS

POWER CONVRRTORS Is: 1885 (Part XXVII )-I969 convertors


251 l-1963 3x36-I965 3895- 1966

Electrotechnical semi-conductor

vocabulary: rectifier stacks

Part

XXVII

Static

power

Polycrystalline Polycrystalline Monocrystalline Monocrystalline

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semiconductor, rectifier equipment semiconductor semiconductor rectifier cells and stacks rectifier assemblies and equipment

4540-l 968